Movable wall structure



April 9, 1938. .J. KlLLlON 2,114,387

MOVABLE WALL STRUCTURE Filed Oct. 17, 1955 4 Sheets-Sheet l m M l M llim L. J. KlLLlON April 19, 1938.

MOVABLE WALL STRUCTURE Filed Oct. 1'7, '1935 4 Sheets-Sheet 2 April 1933- L. .LKILLION 2,114,387

MOVABLE WALL STRUCTURE Filed Oct. 1'7, 1935 4-Sheets-Sheet 3 27 /.9 /5 1' i1; 2 511 /7 I I !!1 {I III /0 April 19, 1938. J. KlLLlON 2,114,387

MOVABLE WALL STRUCTURE Filed Oct. 17, 1935 4 Sheets-Sheet 4 Patented Apr. 19, 1938 UNITED STATES PATENT OFFICE 18 Claims.

In my co-pending application, Serial No. 32, filed January 2, 1935, is disclosed a wall structure embodying an assembly of movable wall panels each comprising a metallic frame faced on either side with plastic material, the panels being so constructed that they can be assembled in edge to edge relation both vertically and horizontally, and being adapted to be severed both vertically and horizontally and the severed parts united to form panels of the desired sizes whereby to construct walls of various dimensions. My present invention herein described also embodies this construction broadly, but furthermore includes other novel and distinguishing features which-render the same superior in many respects and for various purposes, all as hereinafter described.

' The panel in my said prior invention comprises a metallic frame faced with non-metallic sheets and covered with plastic material to provide suitable exterior surfaces, thus providing a relatively light-weight product. In some instances and for various reasons, such a product may not be .as desirable as my present product which utilizes more of the plastic material and eliminates the said non-metallic sheets. Panels constructed in accordance with my present invention will be somewhat heavier than my former product, but, due to the novel design will permit of practical handling and may be manufactured with greater ease and at less expense, all as hereinafter pointed out.

My invention particularly concerns the production of movable wall panels having the two opposite sides or faces thereof forming plaster surfaces and so constructed as to adapt the panels to be assembled in edge to edge relation to form movable partitions or walls, usable if desiredin conjunction with permanent plaster walls, the movable walls to extend from floor to ceiling, the same as permanent walls. The panels are furthermore constructed not only to be thus assembled, but are also so formed that they may be easily and economically altered in respect to 45 height and width, cut to meet obstructions and realtered and reused indefinitely.

The novel panel of my present invention is built upon and. about a skeleton-like metallic frame constructed preferably of light-weight .50 sheet steel formed into suitable and relatively simple uniform pieces which pieces are joined together to produce open rectangular sub-frames, andv two such sub-frames joined together in oppositely disposed and spaced relation produce the skeleton metallic frame upon and about which plastic material is molded to produce my improved panel. The simplicity of such construction will be readily apparent as will also the fact that substantially only two materials, viz., metal 60 and plasticmaterial are used. Economy of materials, lightness of weight and rigidity of the product are features of great importance and to this end the plastic material is molded onto the frame in a manner providing a plane and continuous coating over each sub-frame and, at the same time, the coatings are integrally joined together by sections of plastic material therebetween, which sections are so relatively spaced as to leave the space between the sub-frames substantially hollow and open.

A preferred method which I employ in molding the plastic material over a frame is to provide removable cores, either or both horizontally and vertically, within the space between the subframes' and pour the plastic material intothe frame and around the cores while so confining the frame and the plastic material as to form the coatings and the relatively spaced sections of plastic material integrally joined together. It will be apparent that such coring of the product provides for the reception of concealed Wiring and other service, and a substantial air space within the wall and materially reduces the weight and cost of the product, while at the same time producing a rigid and integral connection between the two coatings. A further feature of the invention is that the frame is substantially open between the two sub-frames thereby permitting the insertion of and removal of cores of substantial size, of any desired shape and in any desired spacing.

The invention permits the use of units of identical structure extending continuously from floor to ceiling except for a space at the base which permits access to the fastening mechanism in erecting and dismantling the wall, which space is closed by any of various ways.

Important features of my invention reside in splicing mechanism which is adapted to align and fasten two sections of cut panels together to form a spliced panel. The novel design of this mechanism permits panels to be altered to any desired size, height or width. Preferably each panel is provided with elongated tubular or channel shaped members, adapted to receive aligning connectors, and these tubular or channel members are efiective to receive said connectors at any out edge, horizontally or vertically, in a panel. Moreover, said tubular or channel members being open ended at the top and bottom edges of the panel permit the vertical assembly of any number of panels, whether cut or not, one on top of the others. Furthermore, panels thus spliced or thus assembled may be separated into r their component parts by moving said connect ors longitudinally in the tubular or channel members so as to clear the line of joint between said component parts. These tubular or channel members likewise provide means to receive removable legs for supporting the panel spaced from the floor.

My invention also embodies, as another important feature, mechanism for aligning and fastening adjacent panels to one another in the wall. This mechanism includes a carrier member having two series of movable clips for simultaneous co-operation with two series of fixed clips mounted on each side wall of the abutting panels, the carrier member being mounted within a recess at the abutting edge of one of the abutting panels by a novel device and arranged for movement in a direction to engage the fixed clips and effect the desired fastening operation. Moreover, the reverse operation disengages the clips, returns the carrier member to its inoperative position within the recess and permits disassembling of the panels.

When the wall is assembled, the joint between adjacent panels may be concealed by filling or pointing with plastic material and this operation is facilitated by open longitudinal spaces left unfilled along the edges of the panel for this purpose, which spaces are prepared in a novel manner for the more secure reception of said pointing material, all as illustrated in the drawings and hereinafter described.

The primary object of the invention consists in the production of a new and improved wall construction of the above described nature. These and other features of the invention will be best understood and appreciated from the following description of a preferred embodiment thereof, selected for purposes of illustration and shown in the accompanying drawings in which,.

Fig. l is a view in perspective showing the metallic frame of a panel of my improved wall structure within a mold box wherein plastic material is applied thereto,

Fig. 2 is a fragmentary view in perspective of the completed panel, partially broken away,

Fig. 3 is a fragmentary edge elevation thereof,

Fig. 4 is a fragmentary view in vertical cross section through the panel,

Fig. 5 is a plan view showing the edge of the panel,

Fig. 6 is a fragmentary View of a horizontal cross section of a vertical edge portion of the panel,

Fig. '7 is a fragmentary view in perspective of the bottom corner of the panel with portions broken away showing the application of the removable leg thereto,

Fig. 8 is a fragmentary view in perspective of the cut end of a vertically cut panel showing the application of the various splicing connectors thereto,

Fig. 9 is a fragmentary view in perspective of two abutting panel assemblies with portions broken away showing the application of the carrier assembly thereto,

Fig. 10 is a View in perspective of a reinforcing fitting for the top corner of the panel,

Fig. 11 is a fragmentary view in horizontal cross section of the vertical edge portion of the panel on a larger scale showing portions of the carrier assembly and the supporting device thereof,

Fig. 12 illustrates one of the elements which form the supporting device for the carrier assembly,

Fig. 13 is a fragmentary exterior View in perspective of a portion of the vertical joining on one face of the wall between two abutting panels with portions broken away and showing the application of a bonding channel for the pointing material,

Fig. 14 is a fragmentary view in perspective of the bonding member shown in Fig. 13,

Fig. 15 is a fragmentary interior view in perspective of a portion of the vertical joining on one face of the wall between two abutting panels with portions broken away and showing the application of a pair of fixed clips.

As in my aforementioned and co-pending application, my invention herein comprises novel wall panels which are adapted to be joined in edge to edge relation, either or both horizontally and vertically, to provide removable walls extending from floor to ceiling and from one wall to another. One such panel in completed form, illustrated in Fig. 2 of the drawings, comprises a skeleton metallic frame having plastic material embodied therewith to provide the complete panel, including the two oppositely disposed plaster wall surfaces. I shall now proceed to describe the construction of this frame by reference to Fig. 1, the frame being therein shown in a mold box wherein the plastic material is applied thereto.

The metallic frame comprises two identical portions of rectangular shape and these I shall term sub-frames. These sub-frames, two of which are shown in Fig. l, are first constructed from metal elements or pieces I and 6 and are then joined together by connecting pieces In and II, as hereinafter described. Each such subframe comprises two oppositely disposed and parallel elements I forming the two vertical ends of the sub-frame, and two horizontally disposed and parallel elements 6 forming the top and bottom ends of the sub-frame, the several elements being preferably flash welded together at their contacting surfaces adjacent to the four corners of the sub-frame.

Each element I has a continuous outturned flange 2 along its outer edge, which flange 2 is preferably corrugated longitudinally to provide stiffness and alignment, and a continuous inturned overhanging flange 3 along its inner edge, said overhanging fiange 3 forming what I will term a raceway, which raceway is used for splicing connectors and other accessories as hereinafter described. Approximately midway between the fianges 2 and 3 is a longitudinally extending outward offset 4, the extent of which offset is preferably such as to locate the inside face of the overhung portion of the flange 3 in the same vertical plane as the inside face of the unoifset portion. At spaced intervals along said element I, tongues with overhanging flanges 5 are struck inwardly out of the offset portion of element I thereby forming an intermittent raceway similar to and opposing the continuous raceway described above for flange 3. As an alternate of these struck-out overhanging tongues 5, a separate continuous Z-bar may be welded or otherwise fastened to the offset portion of element I thus forming a continuous raceway.

Each element 6 at the top and bottom of each sub-frame is a channel section with inturned overhanging flanges which form raceways identical in cross section to the raceways formed by flanges 3 and 5 of the vertical element I except that both raceways of element 6 are continuous. The inner face of element 6 contacts the outer face of the offset portion of element I and the ends thereof engage against the inner faces of the flanges 2 of element I. Starting as near as convenient to the junction of elements 6 and I on the flange 3, as best shown in Fig. 5, a transverse inward offset 1 is preferably made in each element 5, the amount of such offset being sufficient to bring the inner face of the central portion of element 6 into the same vertical plane as the inner face of the overhanging flange 3, which, in conjunction with the similarity of race- Ways as noted above, permits the use of identical splicing connectors for both vertical and horizontal members, all as hereinafter more fully described.

Should the height of the panel make it advisable, additional horizontal elements 8, (Fig. 4), identica to elements 6 and secured to elements I in like manner, may be located in the intermediate portions of the sub-frame, adhesive tape 9 or other means being employed to close the space between the overhanging flanges thereby preventing plastic material from filling the raceways.

It will now be seen, as best shown in Fig. 11, that the inner portion of element I comprising flange 3, flange 5 and the offset portion between and connecting said flanges, is identical in cross section to element 6, whereby identical splicing connectors can be used in splicing together cut panels both vertically and horizontally. It may be desirable from a production standpoint to con struct the elements I in two parts, one part being identical in cross section to element 8, and the other part being a section of that portion of element I which extends outwardly from overhanging flange 5, said two parts being preferably flash welded together to form the required element.

Tongues I2 are preferably struck out of elements I, 6, and 8 to provide bondage for the plastic material. As an alternate of these, however, narrow strips of expanded metal may be employed, such strips being tack welded to the outer face of said elements I, 6, and 8 and preferably being somewhat wider than said faces and adapted to extend a'short distance into the plasticbody of the panel. Such strips should also extend along element I to the inside face of flange 2, and thereby serve also as a bonding medium for the pointing material later described.

t will be noted that elements I, I5, and 8 comprise all the elements of the sub-frame, and inasmuch as elements 6 and 8 are identical, it is apparent that only two types of elements are required to form this sub-frame. This is obviously a distinct advantage from production and economical standpoints as is also the securing of the elements together by a simple welding step. The two sub-frames are secured together in spaced relation by the use of simple metallic elements III and II, welded thereto as shown in Fig. 2. No portion of the elements I, 6, and 8 projects inwardly into the space between the sub-frames beyond the vertical plane of the inside face of the unofiset portion of element I, thus leaving this space entirely free and clear except for the connecting pieces I0 and II. As will become more apparent as. this description proceeds, this free spacing of the sub-frames is of particular advantage in connection with the coring and the application of the plastic material to the frame.

In some instances it may be desirable to have the transverse distance between the inside faces of overhanging flanges 3 greater or less than the transverse distance between the inside faces of the unoifset portion of elements I and this may readily be accomplished by varying the amount of oflset 4 even to the extent of eliminating said offset 4 entirely. Such variation in offset I, however, will obviously necessitate diiferent splicing connectors for horizontal and vertical members.

It will be understood that each skeleton frame comprises two sub-frames secured together in uniformly spaced relation by connecting pieces. II] and II, and said sub-frames are formed from elements I, 6, and 8 prior to being connected together by the pieces I 0 and I I. Also the elements I, 6, and 8 are separately preformed to the shapes shown prior to being assembled to form the subframe. Each sub-frame comprisestwo parallel elements I forming the two vertical sides thereof and two parallel elements 6 forming the top and bottom thereof, elements 8, if employed, being located intermediate of and parallel to the ele ments 6. It will be apparent that the two side edges are identical as also are the top and bottom edges and that the overhanging flanges of the elements are all located on the inside faces of the sub-frames. The web portions of pieces I 0 extend across the space between the sub-frames and are provided with suitable holes to permit the passage of cores therethrough as hereinafter described. The pieces II are of relatively narrow channel shape and the flanged end'sthereof are preferably welded against the outside faces of the elements 6.

While I have above described a preferred sequence of assembling operations it will be understood that the same may be varied as desired, and that it may in some cases be desirable toassemble and weld the entire frame in one operation.

In the longitudinal recesses formed by the flange 2 and offset 4 at the outerface of the element I, (Fig. 11), is preferably inserted a nonmetallic strip I3 which extends vertically between adjacent horizontal elements 6 or 8 as the case may be. Strip I3 preferably fits snugly into the said recess and may be further held securely in place by any convenient means, such as by rivets. This strip maybe of fibre board, rubber or other light weight resilient material preferably having a surface to which the plastic material and the pointing material will adhere, and its outer face is preferably further provided with grooves Zill which serve as an additional bond for the plastic and pointing materials. Said grooves 2'! may be molded or cut or otherwise formed and may extend vertically as shown, horizontally, at an angle, or in any combination thereof. Vertical grooves may be preferable however, as, that with such grooves, no damage to the flange 2 can be transmitted to the plastic body of the panel'until the open groove 21 has been entirely closed or collapsed. With this construction, the flange 2 may be considerably damaged and distorted without fracturing the plastic body of the panel and, moreover, said damage and distortion can be repaired and the flange restored to its normal condition, likewise without fracturing the plastic body of the panel. The vertical grooves 27 also provide means whereby the bonding channel member 45, later described, may be used. When the strips I3 have been installed, the metallic frame is ready to receive the plastic material.

The completed panel as illustrated in Fig. 2 has acovering I8 of plastic material over the outer face of each sub-frame and forming the two oppositely disposed plaster wall surfaces of the panel. These coverings I8 are furthermore integrally connected together by ribs I9 and 20 of the same plastic material, said ribs being Spaced apart and preferably perforated thereby to economize in material, lighten the weight of the completed product and provide accommodation for concealing wiring and other services. It

will be apparent thatsuch construction provides a rigid and substantial panel for the purpose described. In accordance with the preferred form of my invention, the plastic material is applied to the frame in a single and relatively simple pouring operation which I will now proceed to describe.

In molding the plastic material onto the metallic frame I preferably utilize a molding box 82 of the general nature illustrated in Fig. 1. The cover 84 of the box illustrated is removable whereby the frame can be placed within the box and the molded panel removed therefrom, and in some instances it may be desirable to have one of the ends 85 also removable to facilitate these operations. Said ends 85 may be provided with vertical grooves 88 for receiving the ends of the two sub-frames whereby to support the frame and for other purposes to be later described. The front wall 88 is seated at its bottom edge in the groove 98 in the bottom of the box and is movable toward and from the frame about such groove as a pivot. Front 88 may likewise be removable to further facilitate the operations noted above. When the cover 84 is in place and the movable front 88 is in contact therewith, the inside contour of the box corresponds to the external surface of the panel to be produced.

The bottom of the box is provided with a series of openings beneath the molding chamber for receiving therethrough, vertically extending cores 92, these cores passing upwardly through the space between the sub-frames. The two ends 85 and said cores 92 are likewise provided with holes for receiving therethrough horizontally extending cores 94. The inner face of the cover 84 has a downwardly extending rib 98 which fits snugly against the inner faces of the elements 6 and closes the channel openings thereof, this rib and the upper end of cores 92 being in contact during the molding operation. The inner face of the bottom has molding blocks 98 between the cores 92 adapted to fit between the bottom elements 6 of the sub-frames in like manner. Each end 85 of the box also has an inwardly and vertically extending rib 99 extending between the elements I and fitting snugly against the unoffset portion and flanges 3 of elements I.

When the frame and cores have been positioned in the box substantially as shown in Fig. 1 and above described, a measured amount of plastic material, slightly greater than necessary to make the mold, is poured into the box through the space provided between the upper edge of movable front 88 and cover 84, the front 88 being in retracted position at this time. Said plastic material flows inwardly and downwardly about the frame and cores to a level below the top of the box. The movable front 88 is then forced to closed position against the cover 84, during which movement the plastic material is forced into all the open spaces thereby completely filling the box and completing the mold. Vents or overflow holes are provided at the upper corners of the box at I92 and through which holes the excess plastic material is allowed to flow. When the front 88 has been brought into contact with the cover 84 and the flow of plastic material is completed, the excess plastic material at the holes I82 is levelled off flush with the top edges of elements 6 and the plastic material is allowed to take its initial set. The horizontal and vertical cores are then removed and, as soon as practical thereafter, the removable portions of the box are removed and the panel taken from the box. The

panel is thereafter completed by securing a plurality of fixed clips 3| to and along the inner faces of the Vertically extending elements I.

It will be apparent that the vertically extending cores 92 produce holes or passages i8 which extend continuously through the panel vertically, and coincidentally, form outer plastic ribs 19 and inner plastic ribs 20, and furthermore, it will be apparent that the horizontally extending cores 94 produce perforations I! in the plastic ribs I9 and 20 the perforations ll providing continuous horizontal passages through the panel. This novel construction, therefore, not only reduces the weight of the panel but also provides means whereby concealed wiring and other services can be installed in various directions throughout the panel.

It is to be understood that cores 92 and 94 of cross section other than that shown may be readily employed. In some instances, it may be desirable to have plastic ribs 1 9 and 20 horizontally disposed in the panel and this may be readily accomplished by arranging cores 92 to operate horizontally and cores 94 to operate vertically. Furthermore, it may be desirable in some instances to have the panel located in the mold box with elements I in a horizontal position and in contact with the top and bottom of the mold box and this likewise may be readily accomplished by arranging the mold box therefor.

The panel described above may be manufactured in quantity and maintained in stock in standard size, but it is contemplated that it will be necessary on each erection job to adjust the height of the panel to fit ceilings of various heights and, furthermore, to employ one or more panels of width less or greater than standard. The construction of the panel is therefore designed to permit sawing on horizontal and vertical lines and the splicing together of the out sections. Furthermore, said design permits of the vertical assembly of panels, whether cut or not, one on top of the other. In cutting the panel horizontally or vertically, it is entirely practical to saw through the sheet steel of the frame members without injuring the plastic portions of the panel. In this connection, it is to be noted that said sheet steel frame members are located mainly, if not entirely, at the edges of the panel, thereby greatly facilitating the cutting or sowing operation.

It is obviously desirable from an economical standpoint to make panels as large, as to both height and width, as safety and practicability of handling will permit, consistent always with ready interchangeability with the door unit. However, inasmuch as a panel 10 feet high, which is the average ceiling height being considered, may cause difficulty in handling and may, on account of the weight, restrict the width to too narrow a panel to be practical, panels approximately 6 feet high may be desirable. I propose therefore, to make the panels 6 feet high, and to provide for the average height wall by cutting a panel substantially in half, horizontally, and assembling one cut section thereof onto the top edge of a full sized panel the remaining cut section being likewise assembled onto the top edge of another full-sized panel, It will be apparent that, with such arrangement, three standard panels will produce two ceiling-high assemblies, this being a novel feature. It will be understood, however, that the panels may be cut and spliced on any horizontal line.

As an alternate of this 6 foot high panel, a

- insertion into the channels of elements 6.

panel approximately feet high may be desirable, two or more such panels being assembled vertically, one over the other, the upper panel being cut horizontally as may be necessary to secure the desired height. As a second alternate, a panel approximately 3 feet high may be desirable, in which case three or more are assembled in vertical relation, the upper panel being cut horizontally as may be necessary to produce the desired height. In each separate case, however, the panels employed are identical, thus obtaining the maximum degree of standardization.

It is contemplated that the panels and the wall formed thereby shall be supported on legs spacing the panels above the floor, all for the purpose hereinafter described. In order to obtain maximum standardization and facilitate the molding of the plastic material onto the metallic frames, I preferably construct these legs as separate, attachable and detachable members which may be readily applied to and removed from any standard or altered panel. As illustrated in Fig. '7, the mounting elementof said leg is of I-beam construction embodying two parallel flanges 2I integrally connected by a web 22. Each flange 2| is of cross section to fit snugly into the raceways formed by the overhanging flange 3 and overhanging struck-out tongues 5 of element I, and the top end of the flange is rounded to facilitate entrance into said raceways. The web 22 is of width to locate the two flanges 2! in the raceways 35 of two oppositely disposed elements I of the metallic frame of the panel. The length of the leg member is such as to extend the desired distance below the bottom of the panel and a sufficient distance up into the raceways to provide the proper security. On the inner side of Web 22 is welded or otherwise secured, a Z-bar 23 having an offset or web equal to the thickness of the adjacent plastic rib I9. The Z-bar encloses said rib I9 and the web thereof contacts with the bottom of said rib I9 to form a firm support for the panel. Bolts 24 extend through the I-beam web 22, the plastic rib I9 and the upper leg of Z- bar 23, thereby securely to clamp these elements together. A channel bar 25 inserted into one trough of the I-beam provides a smooth face for contact with the floor fitting and a hole 26 through the web of said channel bar 25 and web 22 of the leg is adapted to receive a bolt for securing the leg to the said floor fitting.

It will be noted that the top of the standard panel and all horizontally cut sections thereof present two pairs of perfectly aligned splicing channels 35 and likewise, the vertical edges of all vertically cut sections thereof present two or more like pairs of aligned splicing channels along and within the elements 6 and 8. Such a vertical cut is shown in Fig. 8 and is one of two cut panels which are to be spliced together. In splicing such sections together, various types of splicing connectors may be employed. The connector 28, (Fig. 8), is of I-beam construction and the ends of the flanges thereof are rounded to facilitate The connector 28 is also provided with a centrally located hole through the flanges for receiving a rod 68 which extends outwardly on both sides of the connector. In making a splice, either vertical or horizontal, a connector 28 carrying a rod 68 is forced into each of the splicing channels of one component section, as shown in Fig. 8. The cooperating splicing channels of the complementary section are then forced onto the projecting con- .nector ends and forced toward one another until separated only by rod 68. The rod 68 is then removed and closure is completed with the connector 28 substantially centered with the line joint between the sections, which line joint is hidden by the painting of the completed wall.

Where a portion of the rib 20 prevents the use of a connector of the I-beam type 28, I may use separate connectors 29, (Fig. 8), in like manner as above described. Tubular or cylindrical splic ing connections 30 engaging within holes II of the plastic ribs 20 and in some cases, It may also be employed and these connectors may, in some instances, be long enough to engage like holes in two or more of the ribs 20 and I 9 in each cut panel. It will be apparent that the connectors 28 and 29 can be used in like manner in the channels 3--5 to assemble panels or splice cut sections thereof, vertically.

A novel use for splicing connector 33 arises when itis desired to replace, in an altered panel, the portion that was cut out thereof because of a ceiling beam or other obstruction and thereby to make such altered panel useful in any other location requiring a panel of not greater height. Should the portion that was cut out not be available, any similarly shaped portion With holes registering with the holes I! in the altered panel will serve the purpose. In those more frequent instances where the cut-out portion occurs between the outer plastic ribs I9, splicing connectors 30 will sufiice to make the connection. In those rarer cases where the cut-out portion occurs on the vertical edge of the altered panel, the splicing connectors 30 will be supplemented by a splicing connector 28 engaged into the channels 3-5 of elements I at the altered horizontal edges of the panel and of the portion that is replaced.

It will thus be seen that these splicing connectors 28, 29, and 30, used separately or in conjunction with one another, make possible any desired vertical assembly of panels and any desired alteration in the height or width of a panel, and moreover, make possible the restoration of any altered panel to its original form.

Connection is made between the upper edge of a standard, out or spliced panel and the ceiling by channel shaped ceiling fittings I5, shown in Fig. 9. Each fitting I5 has downwardly and inwardly converging portions for entrance between the oppositely disposed elements I of the panels and between the wings 34 therein and hereinafter described, and the web portion of the fitting is perforated to receive a lag screw or toggle bolt to secure the fitting to the ceiling. In erecting a wall, a series of ceiling fittings I5 is first secured to the ceiling along the lineof the desired wall and located substantially at the points of junction between the panels. These fittings serve accurately to align adjacent panels and hold them in alignment at the ceiling.

In order to align the vertical edges of adjacent panels and to fasten the panels together the following mechanism is provided. Each panel has a series of fixed clips 3|, heretofore mentioned, secured in spaced relation to the inside faces of both elements, I. The clips 3! are arranged one above another at predetermined heights along the member I. Accordingly, when two panels are brought into abutting relation in the wall structure, two of these fixed clips 3| will lie adjacent to each other and in opposed relation on opposite sides of the line of junction between the panels. Referring to Figs. 2 and 9, it will be plain that each fixed clip (H has a corresponding the adjacent panel and that the clips are arranged in pairs upon the elements I so that both walls of each panel will be fastened as will presently appear. Each clip 3| is provided with an overhanging flange on its free end bevelled off at the ends for the reception of a movable clip 8|. The clip 8| is a channel member designed to engage the overhanging flanges of two fixed clips 3| and draw such clips 3| toward each other and hold them in that position (Fig. 9). In addition to the function of firmly holding the panels together at their line of juncture the clips have an additional function of accurately aligning the panels so that their outer surfaces shall exactly coincide and be flush in the wall structure.

As an alternate of, or in conjunction with fixed clips 3|, fixed clips 41 (Fig. 15) may be preferable in some instances, said clips 41 being used in pairs and in cooperation with movable clip 8| in a manner similar to that described above for clips 3|. Each clip 41 is provided with an overhanging flange 48 on its free end bevelled oif at the ends for the reception of the movable clip 8 I. Said flange 48 is likewise provided on its edge face with relatively minute horizontal scorings or teeth 49 which mesh with the scorings or teeth on oppositely disposed clip 41 during engagement with clip 8| and thus positively prevent longitudinal movement between said clips 41 and between adjacent panels. It will be obvious (Fig. 15) that said clips 41 mesh even though the adjacent panels and consequently the clips are at different levels. The main portion of clip 41 preferably has an indented portion 5|] to provide additional flexibility for meshing, in which case, slot 5| or other suitable provision for said indented portion 5|] is providedin the unoifse portion of element Clip 41 is mounted on element I with its edge face substantially flush with the outer face of flange 2.

As a convenient means for positioning and interlocking the movable clips 8| with the fixed clips 3| I provide a novel carrier assembly (Figs. 9 and 11) in the form of a U-shaped channel bar having a main section and a shorter section 36 telescoped within the top end of the main section. The main section is of length somewhat shorter than the floor-ceiling height wherein the wall is to be installed and the section 36 is of relatively short length. The movable clips 8| are mounted in oppositely disposed pairs along and on the outer faces of the section 35, the clips being spaced along the bar a distance equal to the vertical spacing of the clips 3 I. The width of the channel bar 35 is preferably not greater than the width of the clip 8| and the depth or thickness of the bar is such that the pairs of clips 8! mounted thereon are positioned properly to cooperate with the clips 3| mounted on the oppositely disposed elements I as best shown in Figs. 2, 9, and 11.

In Fig. 1.0 I have illustrated a reinforcing fitting adapted to use in the top corner of each panel for connecting the panel to the ceiling and for cooperating with the section 36 to connect the adjacent panels together in edge to edge relation. Each such fitting comprises a short length of I-beam 32 of a structure like the I-beam 2| heretofore described and having two flanges thereof adapted to fit into the raceways 35 of elements I, the bottom ends of the flanges being rounded off to facilitate entrance thereof into the raceways. On one side of the web of the I-beam 32 and at the top thereof is secured an angle plate 33 and on the opposite side thereof is secured a channel member 34. The two wings of the member 34 are preferably flared inwardly to prevent interference with the overhanging flanges 5 of the element and to the inside faces and at the bottom end of these wings is secured in opposed relation a pair of fixed clips 3|. When the I-beam flanges are inserted in the raceways 35 (Fig. 9) the plate 33 contacts with the plastic rib I9 and serves as a stop. Furthermore, when the wall is in assembled relation, this plate 33 is held between the ceiling and the rib l9 against movement in either direction vertically with the carrier assembly.

The short section 36 of the channel bar has its lower end telescoped within the main section 35 and carries a pair of clips 8| at its upper end, a bolt 31 being provided for securing the sections together. It will be understood that clips 8| on the section 36 serve to cooperate with the four clips 3| on the channels 34 (Fig. 9), these clips being the ones most closely adjacent to the ceiling. The section 36 is adjustable within the section 35 to the proper position to serve this function.

It will be apparent that one carrier bar assembly 35-36 is used at the junction between each two adjacent panels thereby requiring only one such assembly for each panel of the assembled wall. In my said co-pending application, the carrier assemblies are preferably mounted in the panels and shipped assembled therein, whereas in my present invention I prefer that the carrier assemblies shall be shipped loose and assembled with the panels on the job, the construction of the bars 3536 and the mountings therefor being such as to make this operation feasible. It may be stated that where these parts are assembled in the shop it occasionally happens that in erecting a wall from both ends inwardly, the two panels at the meeting joint of such wall will both have carrier assemblies at such joint, or possibly neither will have such an assembly at the meeting joint. Both such conditions are obviously incorrect and require modification of the panels to correct the error. It will be apparent that such difiiculty and possibility of error are entirely eliminated by assembling the carrier bars with the panels on the job.

In Fig. 12 I have illustrated one element of a spring wire fitting 38 which I employ in mounting the carrier bars 3536 in and to the panels. Two such elements are assembled together on a rivet 39, serving as a connecting hub therefor, and the two ends 4|! of the fitting are adapted to embrace the bar 35 and engage within the holes therein. The two other ends 42 of the fitting are anchored to the elements I by engaging within holes therein. The extent of the engagement of the ends 40 and 42 within said holes is limited by offsets 4| and 43 adjacent to the ends of the wire elements. Two such fittings 38 spaced a suitable distance apart are utilized for each carrier assembly and it will be apparent that said fittings maintain the carrier bar properly spaced within the vertical open space in the wall at the junction of each two adjacent panels. When the adjacent panels are being assembled, the carrier bar may be held temporarily in the raised position by any convenient means, in which raised and inoperative position, the entire carrier assembly resides within the end recess in one panel, no part thereof projecting out beyond the edge surface of the panel, thereby permitting said panel to be inserted in or removed from the wall structure. When the panel edges are in proper position and the assembly bar lowered, the fittings 38 maintain the bar in vertical position and guide its movement outwardly from within the recess whereby the clips 8i thereon engage over the clips 3| and draw the latter firmly toward one another. It will be apparent that the two elements of the fitting 38 are identical in shape, provide clearance for the assembly 36 therebetween, and are sufliciently flexible to permit the ends to be sprung into and out of engagement with their respective engaging holes. It will be understood that the fittings are also sufiiciently flexible to permit the assembly to move in a vertical line while the clips 8| and 3| are in engagement.

As heretofore stated, the panels and assembled wall are supported on legs 2| in a position leaving a space between the bottom of the wall and the floor. At its lower end each channel 35 is provided with a hole 208 located in the said open space at the bottom of the panel in position where a bar or other tool may be inserted for driving the carrier assembly downwardly and interlocking the movable clips 8| with the fixed clips 3!. Similarly, if it should be desired to remove a panel from the wall structure, the carrier may be moved upwardly to disengage the clips. The space at the bottom of the wall is subsequently enclosed by simple closing pieces, it being contemplated that said closing pieces will be concealed by a conventional base of metal, rubber, or other material, thereby completing the erection of the wall.

By reference to Figs. 2, 5, 6, and 13, it will be noted that the plastic material is extended only partially over the non-metallic strips l3 thereby leaving the vertical edge corners of each panel open to receive pointing material at and over the joint between each two adjacent panels. It may be desirable in some instances to provide additional bondage on these joints and in Fig. 14 I have illustrated bonding channel members for such purpose. This member 45 is preferably made of light gauge sheet metal and has a channel section with a web of width to locate the two legs thereof snugly in two grooves 21 provided one in each of the strips l3 of the abutting panels. The two legs of the channel member reach substantially to the bottom of the grooves .21 and may be slightly flared outwardly to facilitate entrance thereof into the grooves. The web of the member is also preferably struck out to provide tongues 46 to engage with the pointing material and provide additional bondage, and the members 45 may be formed in any convenient and desirable lengths. When the panels have been assembled, the members 45 are snapped into and along the strips 13 in position spanning the joint between the two panels. The gap between the two panels is thereafter filled with the pointing material 52 which binds the members 45 and completes the continuity of the wall surface.

The method I employ to exclude plastic material from the vertical edge portions of the panel,

? leaving them open as noted above, is best shown in Fig. l. Grooves 86, heretofore mentioned and provided in the ends 85 of the molding box for receiving the ends of the two sub-frames, perform this function as will be readily apparent from the drawings. The width and depth of said grooves 86 obviously determine the size of said openings at the vertical edge corners of the panel and said width and depth may be varied as desired. In some instances it may be desired to eliminate said opening at the vertical edge corners of the panel and this is readily accomplished by eliminating said grooves 86 entirely. Moreover, in some instances it may be desired to exclude plastic material from the horizontal edge corners of the panel, thus providing openings at and along said horizontal edge corners similar to the openings described above for the vertical edge corners and this may be readily accomplished by providing grooves similar to grooves 86 in the bottom and top of the mold box for receiving the bottom and top of the two sub-frames.

The general nature of my invention will be apparent from the foregoing description of the specific construction selected for purposes of illustration, as illustrating a preferred embodiment of the invention. It will be understood, however that the design of the various parts may be varied within wide limits and that material other than those specifically described may be employed in the construction.

The objective of the invention is not only to produce a flush and movable plaster wall comprising panels of identical size and of simple construction, but to employ only such materials as are most universally used, the easiest to work and the least expensive and, moreover, to limit the number of different materials used, as far as possible. On this account, the materials employed have been confined substantially to two, gypsum and steel.

I prefer to employ gypsum inasmuch as it answers the above requirements in an outstanding manner as compared with other plastic materials. Furthermore, I employ a unique construction of the gypsum portion of the panel together with a novel means of producing-said construction thereby to reduce the weight for practical and economical purposes.

The desired results can best be obtained by supplementing the gypsum portion described above with a structural frame, and. to form this frame I prefer to use thin gauge sheet steel as it likewise answers the above mentioned requirements in an outstanding manner. The novel frame which I employ not only lends itself to quantity production and makes possible the construction of the plastic portion of the panel but reduces the weight and increases the economy of the product.

In addition to the above, the detachable leg, the simple splicing connectors making possible any desired alteration and re-alteration, the carrier assembly operating on both walls of the panels simultaneously together with its unique mounting device, and the non-metallic edge strips 'with their grooves and supplementary bonding channel make this invention a new and valuable contribution to the building industry.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

1. A wall panel comprising a metallic frame embodying two frame members and means holding said members in relatively spaced relation, a covering of plastic material providing a continuous exterior surface over the outer face of each of said members, and relatively spaced sections of plastic material integral with and connecting said coverings therebetween.

2. The wall panel defined in claim 1 wherein said metallic frame embodies members having longitudinal openings therein to accommodate the insertion of splicing connectors longitudinally thereinto.

3. The wall panel defined in claim 1 wherein said sections of plastic material are ribs substantially coextensive with one dimension of the panel and perforated whereby lightening the weight of the panel and permitting the insertion of conduits through the panel in one direction between the ribs and in another direction through the perforations.

i. A wall panel comprising a skeleton metallic frame embodying two opposed sub-frames joined together in spaced relation, a covering of plastic material over the outer face of each sub-frame and providing a continuous exterior surface thereover, and relatively spaced sections of plastic material integral with and connecting said coverings therebetween.

5. The wall panel defined in claim 4 wherein one of said sub-frames embodies a channel bar extending along each of two opposite edges thereof and open to the adjacent edges and other channel bars extending transversely of and connecting the first named channel bars.

6. The wall panel defined in claim 4 wherein said sub-frames have opposing and relatively spaced channel bars at two opposite edges of the panel providing an open space therebetween extending continuously along each of said edges, and means carried by the panel within said spaces for use in joining the panels in edge to edge relation to an adjacent panel.

7. A wall panel comprising a metallic frame, non-metallic longitudinal strips carried by the frame at two oppositely disposed edges thereof, a covering of plastic material over each of two opposing faces of the frame and providing a continuous exterior surface thereover, and relatively :spaced sections of plastic material integral with and connecting said coverings therebetween, said coverings of plastic material extending short of said edges to an extent leaving portions of said strips exposed for the reception of pointing material.

8. The wall panel defined in. claim '7 wherein said non-metallic strips are provided with grooves in their outer faces for the purposes described 9. The wall panel defined in claim '7 wherein the said exposed portions of the non-metallic strips are each provided with a groove within its outer face, and extending longitudinally of the strip and along a line spaced from the outer edge of the strip.

10. A wall structure comprising panels having abutting edges, each panel having its outer face recessed along a line spaced from said edges, a metallic channel member having a web spanning said edges and laterally disposed legs inserted into said recesses, and a covering of plastic material concealing said edges, the: channel member and said recesses.

11. A wall structure comprising two panels having edges in abutting relation, each such panel having a recess extending along and within each of said edges, and means within said recesses for securing the panels together in said abutting relation, said means comprising a plurality of pairs of clips rigidly fixed to the panels within both of said recesses and a bar extending longitudinally of and within one of said recesses and carrying a plurality of oppositely disposed clips on oppositely disposed faces thereof for cooperating with the fixed clips of both panels to draw and hold the panels together, the bar being mounted on one panel within its recess for movement to effect said cooperation.

12. The wall structure defined in claim 11 in which the said bar embodies two sections in telescopic relation, each such section carrying a plurality of said oppositely disposed clips for cooperating with the fixed clips, and means for securing the sections in telescopically adjusted relation.

13. A wall structure comprising two panels having edges in abutting relation, each panel comprising a metal frame, a covering of plastic material over each of two opposing faces thereof and providing a continuous exterior surface thereover, relatively spaced sections of plastic material integral with and connecting said coverings therebetween, said sections of plastic material having preformed openings extending thereinto from said abutting edges, and a splicing connector extending across the abutting joint and into said openings of the two panels.

14. A wall panel comprising a frame faced on opposite sides with plastic material and having a recess extending along and within each vertical edge thereof, means within each recess providing raceways open to the top edge of the panel, and a fitting carrying flanges extending into the raceways and carrying clips for use in securing the panel to an adjacent panel, said fitting having an offset portion engageable between the panel and a ceiling for preventing vertical movement of the fitting.

15. A wall panel comprising two oppositely disposed slabs of plastic material having two oppositely disposed and exterior faces thereof in parallel relation, and sections of plastic material between and integrally connecting said slabs and so relatively spaced as to leave passages extending through said panel in two substantially rightangular directions between said slabs and parallel to said faces.

16. A wall panel comprising a metallic frame, a covering of plastic material over each of two opposing faces thereof and providing a continuous exterior surface thereover, and relatively spaced sections of plastic. material integral with and connecting said coverings therebetween, said covering of plastic material extending short of two oppositely disposed edges of the panel thereby leaving a longitudinal gap at such edges to be filled in with pointing material.

17. A wall panel comprising a metallic frame, a covering of plastic material over each of two opposing faces thereof and providing a continuous exterior surface thereover, relatively spaced sections of plastic material integral with and connecting said coverings therebetween, the interior of the panel being provided with means forming longitudinally extending raceways open to the bottom edge of the panel, and removable legs having portions for engaging within said raceways and supporting the panel spaced from the floor.

18. A movable wall structure comprising two panels with abutting edges, each panel including a metallic frame and means providing two opposing wall surfaces on two opposite sides of the frame, said frame including members having raceways adapted to receive legs therein whereby to space the panel above the floor, a series of clips oppositely arranged adjacent to said abutting edges, and means to lock or unlock said clips through the space below the panel and above the floor.

LOUIS J. KILLION. 

